Micro Welding

Micro welding, sometimes reffered to as precision welding has been specifically designed for the welding of small often delicate components. The processes and equipment used require the use of heat energy that is in a tightly controlled environment. The micro welding process sets up the weld by depositing fine blobs of weld to the components to be fused. Often the welding bead is no more than .065 and may even go as small as .005.

As Micro welding is a state of the art process that is used for welding small areas. Often the micro weld requires the surrounding area to be minimally effected by heat, requiring precise heating of the weld to only allow proper fusion of the joint.

Micro welding requires the use of miniature TIG welding equipment (Gas Tungsten Arc) that is not much larger than a pen. Micro TIG welding is the latest in tool welding technology. Micro TIG offers superior control of weld placement while maintaining structural integrity with less residual stress.

Utilizing the assistance of arc micro welding it is possible to restore components which are challenging to weld; put together very small parts in to complicated structures , tools involving high alloy material and also repair of costly molds.

Other methods of micro welding utilize lasers. Micro laser welding makes use of tiny solid-state options possessing fractional energy to accomplish the job. Nonetheless, applications which can be incorporated into automated procedures tend to be the most suitable applications for laser micro welding. This style of minuscule welding additionally produces some of the very best qualities for welded joints

Tig Welding Basics

TIG Welding Is Used for Many Metals

tungsten inert gas weldingTungsten inert gas welding, or TIG welding, is additionally referred to as GTAW, or simply gas tungsten arc welding. Whilst much like gas welding. This utilizes a tungsten electrode to produce the actual arc as well as heat for your weld.

The advantages to utilizing TIG welding will be it can easily be employed to weld much more types of metals as well as alloys. You will get thoroughly clean welds. You won’t get spatter or messy welds that require cleanup by grinding. Tig welding produces an excellent robust, clean, plus neat and tidy weld.

Before starting welding you need to make sure that you take all the proper safety precautions. You need to have a good quality welding mask preferably for tig welding. The light given off by arc welding is enough to burn your eyes, and it can burn your skin, like a sunburn. Make sure that you are wearing leather gloves and a leather welding jacket to protect your arms and neck. Make sure that your jacket fastens all the way up to your neck. You want to wear heavy cotton shirts and trousers. You also need to wear heavy closed shoes. You should have a welding screen and warning sign so others can avoid the area, and you need to make sure it’s well ventilated.

Once you have set up all the safety precautions, it’s time for you to get down to welding. Before you can do any welding you need to make sure that you have the right electrode. Different metals need different tungsten electrodes. Grind the electrode down so that it has a nice point. When you are welding that point will get worn down to a rounded tip. A pointed electrode tip gives you a better weld. It will be smaller and more directed.

Make sure to grind away from you so you don’t contaminate the electrode. After you grind the tip, you need to put the electrode in the right holder. Then you choose the right settings on the welding machine. Different metals need different settings. Check your manual for the right settings.

Clean your metal and your table. That will give you the best welds. Clamp your metals down to your table so they don’t move when you are welding.

To start a weld keep the tip about an inch from your metal. You don’t want the tungsten tip to actually touch the metal. You want to heat your metal quickly so you can start the weld pool from the arc created.  Use the electrode to create a weld pool then add filler material as required.

The way you weld depends on what metal you are welding. After you finish your weld you might want to grind it down, depending on if it is going to be seen or not. That will also give you the chance to check your weld to make sure that there are no holes or gaps.

It may take some practice to get good welds, but don’t be discouraged. Once you have it, you can weld just about anything.

Learning How To Tig Weld

Once you learn how to tig weld you will be considered a serious welder and for many an artist. Tig welding really is an art form. Most people will not see this however creating the perfect bead of weld in the place you want it does require skill and creativity.

how to tig weldThe Tig welding process can be used to weld many metals, brass, aluminium, steel, copper, bronze, nickel alloys and gold.

Tig welding or tungsten inert gas welding begins using a tungsten electrode that once struck creates an arc to heat and fuse metals to be welded. The tungsten electrode does not actually touch the work but is held at a distance from the work that is enough to create heat and, with the aid of a filler electrode, fusion occurs.

To eliminate the need for flux a shielding gas is used in a similar manner to mig welding and is delivered via  the tig torch itself. The gas, generally pure Argon, protects the weld from outside contamination.

Setting up the Tig welding machine is a key component to learn how to tig weld and can be summarized as;

–          Set up gas supply to tig torch

–          – Set up welding inverter power. This all depends on the type and thickness of the metal / alloy to be welded. This should be available in the welding machine manual.

–          Attach earth clamp.

–          Grind tungsten electrode to a point, the grinding is important, grind the point along the length of the electrode and not around it, the length of the grind should be two and a half times the diameter of the electrode, grind a small flat at the tip, not a sharp point. Grinding in this manner will prevent any welding ‘wander’.

–          To start welding the torch needs to be held at between 70 to 80 degrees. Keep the tip about 1/8 to ¼ inch from the work being welded. Practice controlling the arc ‘puddle’ width at approx ¼ inch wide.

–          Next add filler rod to the weld in small blobs or dabs, always try to keep the torch at a constant distance from the work and a smooth weld speed. Push the weld rather than pull.

Once you learn how to tig weld it is a most satisfying accomplishment. Tig welding is a very clean process and requires little or no clean-up. This makes it ideal for welds that are highly visible in a decorative situation such as furniture, stainless steel or aluminium components and art work.

TIG Welders – Lightweight Welding Power

tig weldersTIG welders are commonly available as a Tig AC/DC power source that allows manual electrode welding as well as TIG welding. Modern machines contain microprocessors that give full digital control that results in perfect tig welds. TIG welders of this nature are rated from around 170 A to 300A, they are lightweight, portable and excellent welding machines suited for construction and maintenance work.

Larger TIG welders will run from 400 to 500A output. Machines of this nature also fully digital controlled. Applications include plant construction, aerospace and shipbuilding, pipeline construction and installations

When TIG welding, the operator has more control over the whole process of welding. Unlike other welding types Tig welders use tungsten electrodes that are non consumable. Tungsten is used as the melting point is extremely high, allowing the operator to introduce a filler rod to the weld. Many in the welding industry use tig welders to weld non ferrous metals such as magnesium, copper, and aluminum as well as stainless steel.

The Advantages of TIG Welders

The electrodes used with TIG welding are non-consumable, while other types of welding, like tig welderarc and mig welding use electrodes that are consumable. There are advantages with both methods but with TIG welders there is no need to stop in the middle of a project and replace the rod that has been used up. As one might expect, stopping at a critical point can cause an imperfection in the quality of the finished product. With the undisturbed work that can be done with the TIG system, the overall quality is much better.

TIG welders are a good choice when working with non-ferrous metals like copper, magnesium, and aluminum.

Minor disadvantages of TIG Welders

If you have ever wondered why there are so many different welding techniques as well as equipment, the answer is simply that there are different situations that require welding of a different kind using an array of different equipment. For this reason tig welding is a somewhat specialized feild.

For one thing, TIG welding is more complicated and requires more skill and better training in order to carry it off right. The welder using a TIG welding machine must have much greater accuracy and control in directing the tig torch and using the filler rods. Maintaining the arc in the correct position and the right distance from the piece they are working on is critical.

Welding with a tig machine is more time consuming than most of the other methods, but you must remember that this time means the finished work will be much higher quality, making it worth the time it takes to complete. Wearing a quality welding helmet is essential as the arc created from tig welders is much brighter than conventional welders.